Risk Failure Mode and Effect Analysis (RFMEA)

 

                                  POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (RISK FMEA)

 

Item

 

Potential Risk Responsibility

 

PFMEA Number

  

Product Name & Model

 

Key Date

 

Prepared by

  

Core Team

 

Date (Original)

  

Date (Revised)

  

Op Seq #

Process/ Product/ Function/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

 

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

 
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
                      
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
                      
                      
                      

Design Failure Mode and Effect Analysis (DFMEA)

 

                                  Design FAILURE MODE AND EFFECTS ANALYSIS (PRODUCT FMEA)

 

Item

 

Design Responsibility

 

DFMEA Number

  

Product Name & Model

 

Key Date

 

Prepared by

  

Core Team

 

Date (Original)

  

Date (Revised)

  

Op Seq #

Design Part/ Product /Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

 

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
                      
                      
                      

Process Failure Mode and Effect Analysis (PFMEA)

 

                                  POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

 

Item

 

Process Responsibility

 

PFMEA Number

  

Product Name & Model

 

Key Date

 

Prepared by

  

Core Team

 

Date (Original)

  

Date (Revised)

  

Op Seq #

Process Function/ Task/ Tool/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

 

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
                      
                      
                      

System Failure Mode and Effect Analysis (SFMEA)

 

                                  SYSTEM FAILURE MODE AND EFFECTS ANALYSIS (SYSTEM FMEA)

 

Item

 

System Responsibility

 

SFMEA Number

  

Product Name & Model

 

Key Date

 

Prepared by

  

Core Team

 

Date (Original)

  

Date (Revised)

  

Op Seq #

System Architecture/ Execution/ Function/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

 

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
                      
                      
                      

Software Failure Mode and Effect Analysis (SWFMEA)

 

                                  SOFTWARE FAILURE MODE AND EFFECTS ANALYSIS (SOFTWARE FMEA)

 

Item

 

Software Responsibility

 

SWFMEA Number

  

Product Name & Model

 

Key Date

 

Prepared by

  

Core Team

 

Date (Original)

  

Date (Revised)

  

Op Seq #

Software Architecture/ Algorithm/ Code/ Function/ Requirment

Script/Code Function ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

 

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
                      
                      
                      

Operations Failure Mode and Effect Analysis (OFMEA)

 

                                OPERATIONS  FAILURE MODE AND EFFECTS ANALYSIS (OPERATIONS FMEA)

 

Item

 

Operations Responsibility

 

OFMEA Number

  

Product Name & Model

 

Key Date

 

Prepared by

  

Core Team

 

Date (Original)

  

Date (Revised)

  

Op Seq #

Operation Function/ Requirment

Product Characteristics ID/Description

Potential Failure Mode

Potential Effect(s) of Failure

Severity

Classification

Potential Cause(s) of Failure

Current Process

RPN

Recommended Action

Responsible

Date

Action Results

 

Controls Prevention

Occurance

Controls Detection

Detection

Actions Taken & Completion date

Severity

Occurrence

Detection

RPN

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
            

 

       

 

 
                      
                      
                     

Design Failure Mode and Effect Analysis (DFMEA)

 

(Design FMEA)

 

System :

                    

Subsystem:

            

FMEA Version :

V0.1

      

Component :

    

Design Responsibility :

      

Page:

       

Model Year (s)/ Program(s) :

           

Prepared by:

       

Core Team :

    

Key Date :

      

FMEA Date (Orig.) :

       
                     

Item / Function

Requirement

Potential Effect(s) of Failure

Severity

Potential Failure Mode

Characteristics

Classification

Potential Cause(s) of Failure

Current Design

RPN

Recommended Action

Responsibility & Target Completion Date

Action Results

 

Controls Prevention

Occurrence

Controls Detection

Detection

Actions Taken Completion Date

Severity

Occurrence

Detection

RPN

 
            

 

      

 

 
            

 

      

 

 
   

1

     

1

 

1

1

   

1

1

1

1

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
            

 

      

 

 
                     
                     
                
                

 

       

APPEARANCE APPROVAL REPORT

       

PART NUMBER

   

DRAWING NUMBER

     

APPLICATION

     
  

Aluminium part

     

PART NAME

   

BUYER CODE

     

E/C LEVEL

   

DATE

 
       

SUPPLIER NAME

   

MANUFACTURING ADDRESS

         

SUPPLIER CODE

 

LVL d.o.o.

   

LOCATION

           

REASON FOR

 

PART SUBMISSION WARRANT

 

SPECIAL SAMPLE

 

RE-SUBMISSION

OTHER

 

SUBMISSION

 

PRE TEXTURE

 

FIRST PRODUCTION SHIPMENT

 

ENGINEERING CHANGE

  
         

APPEARANCE EVALUATION

      
                
   

SUPPLIER SOURCING AND TEXTURE INFORMATION

        

   PRE-TEXTURE

   
            

   EVALUATION

   
       

   CORRECT

   
            

   AND PROCEED

   
            

   CORRECT AND

   
            

   RESUBMIT

   
            

   APPROVED TO

   
            

   TEXTURE

   
 
                
         

COLOR EVALUATION

      
                

COLOR SUFFIX

               

COLOR HEX

               

TRISTIMULUS DATA

DL*

              

Da*

              

Db*

              

DE*

              

CMC

              

MASTER NUMBER

               

MASTER DATE

               

MATERIAL TYPE

               

MATERIAL SOURCE

               

HUE

RED

              

YEL

              

GRN

              

BLU

              

VALUE

LIGHT

              

DARK

              

CHROMA

GRAY

              

CLEAN

              

GLOSS

HIGH

              

LOW

              

METALLIC BRILLIANCE

HIGH

              

LOW

              

COLOR SHIPPING SUFFIX

               

PART DISPOSITION

               
                
 

SUPPLIER SIGNATURE

PHONE NUMBER

DATE

CUSTOMER REPRESENTATIVE SIGNATURE

DATE

      
                
                
              

Control plan

 

Prcess Control Plan (PCP)

 
 

Prototype                   Pre-Launch                 Production

 

Control Plan Number

 

Key Contact& Phone

 

Date (Original)

Date (Revised)

 

Part Number/Latest change level

 

Core Team

    

Part Name/Description

 

Supplier/Plant approval date

    

Supplier/Plant

 

Supplier Code

 

Customer Quality Approval date (if required)

  
              

Op Seq #

Operation Description                   (Do this, to this, with this)

Machine Device/Jig/tools for manufacturing

Characteristics

Class

Methods

Reaction Plan

 

No

Product

Process

Prodcut/Process specification Tolerance

Evaluation Measurement technique

Sample

Control Methods

 

Size

Frequency

 
              
              
              
              
              
              
              
              
              
              
              
              
              
              
              
              
                                                                                                                                                                                                                                                                                                                        

Advanced Product Quality Planning ( APQP) Process  

 

Comment:

                                                                                                                                                                                                                                                
                                                                                                                                                                                                                                                 
 

Date of Issue:

  

Form Number: 01

                                                                                                                                                                                                                                                
 

Supplier

     

Date

                                                                                                                                                                                                                                                 
                                                                                                                                                                                                                                                                   
 

Location

     

Review #.

                                                                                                                                                                                                                                                 
                                                                                                                                                                                                                                                                    
 

Supplier Code

     

Project

                                                                                                                                                                                                                                                 
                                                                                                                                                                                                                                                                    
 

Risk Assessment

 

Part Name

                                                                                                                                                                                                                                                 
                                                                                                                                                                                                                                                                    
 

New :

             

Part Number

                                                                                                                                                                                                                                                 
                                                                                                                                                                                                                                                                    
   

Other Risks

    

User Plant (s)

                                                                                                                                                                                                                                                 
                                                                                                                                                                                                                                                                    
                                                                                                                                                                                                                                                  
 
[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'APQP Team Participants; Supplier, Sub-tier Suppliers, and BorgWarner Personnel, including all affected Plants.'
NOTE: '']

Team Members

Company/Title

Phone

e-mail

                                                                                                                                                                                                                                                
                                                                                                                                                                                                                                                     
                                                                                                                                                                                                                                                     
                                                                                                                                                                                                                                                     
                                                                                                                                                                                                                                                     
                                                                                                                                                                                                                                                     
                                                                                                                                                                                                                                                  
 

Build Level

Prototype

Required Date

 

Quantity


[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Define the Number of Special Characteristics that may be customer specific including: '
NOTE: '• "Significant"'
NOTE: '• "Major"'
NOTE: '• "Critical"'
NOTE: '• "High Impact"'
NOTE: 'that requires on-going statistical capability and/or requires validation in the Process Control Plan.'
NOTE: '']

Special Characteristics

Comments

                                                                                                                                                                                                                                                
                                                                                                                                                                                                                                                  
                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                  
 

APQP Elements

GYR


[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Status = Green, Yellow or Red as defined in definitions tab.'
NOTE: ''
NOTE: '']

G

Program

Supplier

Closed

Champion


[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'The current revision & date for the applicable document '
NOTE: '']

Document


[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Contingency plans are required for any element that has a yellow or red status.'
NOTE: '']

Remarks

TIMELINE

                                                                                                                                                                                                                                                

 

Status

Y

Need

Timing

Date

Name

Revision

 

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

22

24

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

                                                                                                                                                                                                                                                
  

R

Date

Date

  

Date & Rev.

 

                                                                                                                                                                                                                                                                                                    
 

Phase 1.0 : Kick-off & Planning

                                                                                                                                                                                                                                                                                                    
 

1) Project team established

                                                                                                                                                                                                                                                                                                            
 

2) Specification and system review

                                                                                                                                                                                                                                                                                                            
 

3) Project plan review

                                                                                                                                                                                                                                                                                                            
 

 - Preliminary Capacity study

                                                                                                                                                                                                                                                                                                            
 

 - Preliminary sub-supplier plan

                                                                                                                                                                                                                                                                                                            
 

 - Preliminary Traceability tree with BoM.

                                                                                                                                                                                                                                                                                                            
 

 - Process Equipment / Control equip/ Prod. gauges

                                                                                                                                                                                                                                                                                                            
 

 - Prototype Tooling (with specification release date)

                                                                                                                                                                                                                                                                                                            
 

 - Production Tooling (with specification release date)

                                                                                                                                                                                                                                                                                                            
 

4) Feasibility

                                                                                                                                                                                                                                                                                                            
 

5) PPAP level agreed

                                                                                                                                                                                                                                                                                                            
 

Phase 2.0 : Process & Design Development

                                                                                                                                                                                                                                                                                                    
 

1) Process flow chart

                                                                                                                                                                                                                                                                                                            
 

 - Floor plan layout

                                                                                                                                                                                                                                                                                                            
 

2 Process-FMEA

                                                                                                                                                                                                                                                                                                            
 

 - Process Equipment / Control equip / Prod. gauges

                                                                                                                                                                                                                                                                                                            
 

 - Important characteristics defined and agreed

                                                                                                                                                                                                                                                                                                            
 

3) Measurement System Plan

                                                                                                                                                                                                                                                                                                            
 

 - Meassurement system analysis plan

                                                                                                                                                                                                                                                                                                            
 

 - Preliminary Process Capability Study Plan

                                                                                                                                                                                                                                                                                                            
 

4 Prelimnary Control Plan

                                                                                                                                                                                                                                                                                                            
 

5) Process Instructions

                                                                                                                                                                                                                                                                                                            
 

 - tooling maintenance management plan

                                                                                                                                                                                                                                                                                                            
 

 - machine maintenance plan

                                                                                                                                                                                                                                                                                                            
 

 - employee skill maintenance plan

                                                                                                                                                                                                                                                                                                            
 

6) Packaging Evaluation

                                                                                                                                                                                                                                                                                                            
 

Phase 3.0 : Product & Process Validation

                                                                                                                                                                                                                                                                                                    
 

1) Control Plan

                                                                                                                                                                                                                                                                                                            
 

 - work instructions

                                                                                                                                                                                                                                                                                                            
 

2) PPAP

                                                                                                                                                                                                                                                                                                            
 

3) Production Trial Run

                                                                                                                                                                                                                                                                                                            
 

 - Run at Rate for capacity

                                                                                                                                                                                                                                                                                                            
 

 - Measurement System Evaluation

                                                                                                                                                                                                                                                                                                            
 

 - Process Capability Study

                                                                                                                                                                                                                                                                                                            
 

4) Production Part Approval (PPAP)

                                                                                                                                                                                                                                                                                                            
 

 - PSW / I.S.I.R

                                                                                                                                                                                                                                                                                                            
 

 - PPAP Sign Off

                                                                                                                                                                                                                                                                                                            
 

Phase 4.0 : Confirmation of tools & production

                                                                                                                                                                                                                                                                                                    
 

 - Trial casting successfully validated

                                                                                                                                                                                                                                                                                                            
 

 - EMPB confirmed

                                                                                                                                                                                                                                                                                                            
 

 - PSW confirmed

                                                                                                                                                                                                                                                                                                            
 

 - Open Actions list reviewed and closed

                                                                                                                                                                                                                                                                                                            
 

 - Close APQP

                                                                                                                                                                                                                                                                                                            
 

 - Open Continuous Imrpovement Plan (if remaining issues)

                                                                                                                                                                                                                                                                                                            
                                                                                                                                                                                                                                                                                                                        
                                                                                                                                                                                                                                                                                                                        
 

Open Issues - Action Plans

                            
 

APQP Element

Date

Description of Concern

Actions Taken / Implemented

Responsible

Completion Date


[ANNOTATION:

ON '2021-07-15T00:00:00'
NOTE: 'Open / Closed'
NOTE: '']

Status

                            
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                              
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    
                                    

Meeting Log

                                                
   

Date of APQP Meetings

                                                

Name of Participant

Topic

Kick-off

1

2

3

4

5

6

7

8

9

                                                
                                                            
                                                            
                                                            
                                                            
                                                            
                                                            
                                                            
                                                            
                                                 
                                                            
                                                            
 

Risk/Status Assessment

                                                                         
 

Risk

Color

Definition

                                                                         
 

High

Red

Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work plan does not achieve program targets.

                                                                         
                                                                          
 

Moderate

Yellow

Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieve

program targets, and has been approved by the appropriate Management Team

                                                                         
                                                                          
 

None

Green

Target dates and deliverables are on track and meeting objectives.

                                                                         
                                                                          
                                                                                                
                                                                                                

INTERNAL VALIDATION FOR TOOLS

                                                            

Validation Plan Numr

    

Key contact/ Phone/ e-mail

  

Date (Orig.)

  

Date (Rev.)

                                                                

Številka plana nadzora

    

Ključna kontaktna oseba/ telefon/ e-mail

  

Datum izdaje (Orig.)

  

Datum zaporedne izdaje (Rev.)

                                                                

1

                                                                           

Part Number/Latest Change Level

    

Core Team

  

Customer Engineering Approval/Date (If Req'd.)

                                                                   

Številka dela/Raven tehnične spremembe

    

Člani tima

  

Odobritev razvoja kupca/Datum (če je zahtevano)

                                                                   
        

Customer approval

                                                                   
                                                                            
                                                                            

Part Name/Description

    

Supplier/Plant Approval/Date

  

Customer Quality Approval/Date (If Req'd.)

                                                                   

Naziv/Opis dela

    

Odobritev dobavitelja/Lokacija/Datum

  

Odobritev kontrole kakovosti kupca/ datum (če je zahteva)

                                                                   
                                                                            

Supplier/Plant

  

Supplier Code

 

Other Approval/Date (If Req'd.)

  

Other Approval/Date (If Req'd.)

                                                                   

Dobavitelj- proiz. lokacija

  

Šifra dobavitelja

 

Ostale odobritve/Datum (če je zahtevano)

  

Ostale odobritve/Datum (če je zahtevano)

                                                                   
                                                                            

Nr. of validation step (Št. Koraka)

Tool VALIDATION STEPS  (KORAKI VALIDACIJE)

                                                                          
                                                                
                                                                

01

Tool Completeness (Kompletnost orodja)

Drawing number and version (Št. Risbe in verzija)

Number of tool parts (Št. delov orodja)

Date of Tool Completion (Datum izdelave orodja)

Tool Completness Documentation (Dokumentacija kompletnosti orodja)

Certificates, Confrimation forms, Other documentation (Certifikati, Potrdila in Ostala dokumentacija)

Technical Remarks and Comments (Tehnične Opazke in Komentarji)

                                                            
                                                                  

02

Trial Die Casting (Preizkusno litje)

Number of castings (Št. Litij)

Material (Material)

Material Supplier (Dobavitelj materiala)

Producer (Izvajalec)

Machine (Stroj)

No. of samples

(Št. vzorcev)

Date of manufacturing (Datum vzorčne serije)

Parameters (Parametri)

Comments (Komentarji)

                                                            
                                                                     
                                                                     
                                                                     

03

Measurements (Meritve)

Number of measurements (Št. Meritev)

Function (Funkcija)

Size (Velikost)

Frequency (Frekvenca)

Product- process

specification- tolerance (Proizvod- proces

Specifikacije- tolerance)

Method of measurement (Metoda merjenja)

CC and SC (Kritične mere)

Results (Rezultati)

Date of measurement (Datum meritve)

Controler Name (Ime Kontrolorja)

MR - Measurement documentation (MR - Dokumentacija meritev)

                                                            
                                                                       
                                                                       
                                                                       

04

Measurement Protocol (Merilni protokol)

MR acceptable (MR sprejemljiv)

MR validation document (MR dokument validacije)

Nr. Of measured parts (Št. Pomerjenih kosov)

Number of gold samples (Št. zlatih vzorcev)

PPAP documentation (PPAP dokumentacije)

Identificaiton of additional measurements and QA (Identifikacija drugih meritev in QA)

Comments (Komentarji)

                                                            
                                                                   

05

Submitting samples with measuring protocol (Posredovanje vzorcev z merilnim protokolom)

Measurement documentation sent to Customer (Merilna dokumentacija poslana kupcu)

PPAP sent to Customer (PPAP poslan kupcu)

PSW sent to Customer (PSW poslan kupcu)

PPAP documentation change (PPAP dokumenti sprememb)

MR documentation change(PSW dokumentacija sprememb)

Date of submittion (Datum posredovanja)

Number of samples (Št. vzorcev)

Sent to customer for inspection Y / N (Poslano kupcu za pregled)

Comments (Komentarji)

                                                            
                                                                     

06

Customer Confirmation (Potrditev s strani kupca)

PSW confirmation(PSW potrditev)

Corrections of PPAP, MR (Korekcije PPAP, MR)

Implementation of PPAP, MR (Implementacija PPAP, MR)

Date of Confirmation (Datum potrditve)

Date of Implementation (Datum implementacije)

Comments (Komentarji)

                                                            
                                                                  

07

First Series Manufacturing (Proizvodnja prve serije)

Date of manufacturing (Datum vzorčne serije)

No. of products

(Št. vzorcev)

Ability to process CP / CPK (Sposobnost procesa CP /CPK)

Control according to QP (Kontrola po QP)

Controler Name (Ime Kontrolorja)

Comments (Komentarji)

                                                            
                                                                  
                                                                            
                                                                            
              
              

This is only an example of internal validation of tool.

             
              

First 15 rows represent the HEADER of Form. It includes: validation plan number, part number, last change, part name, description, supplier, plant, supplier code, key contact people, dates and approval dates, customer quality approval, customer engineering approval, core team.

       
       
       
       
       
       
       
       

1 STEP - TOOL COMPLETNESS: Step includes tool documentation, check list for all tool parts, validations if tool was completed. It also adds an attachements of documents such as drawings, forms,  certificates, validations..etc.

       
       
       
       

2 STEP - TRIAL DIE CASTING: We start the function test if tool works correctly. We prepeare the tool by steps of assembly and parameters. We start the trial die casting of small quantities 10 - 100 pieces. We record all parameters and figures of trial die casting.  We prepeare samples for approval process, measurments, x-rays, spectroanalysis,..etc.

       
       
       
       

3 STEP - MEASUREMENTS: We make the measurments, x-ray, spectoanalysis and create reports.

       
       
       
       

4 STEP - MEASUREMENT PROTOCOL: We check the measurement results and completed PPAP documentation.

       
       
       
       

5 STEP - SUBMITTING SAMPLES WITH MEASUREMENT PROTOCOL: We sent the PPAP documentation, MR results and samples to customer.

       
       
       
       

6 STEP - CUSTOMER CONFIRMATION:  PSW confirmation from customer.

       
       
       
       

7 STEP - FIRST SERIES MANUFACTURING: This step is taken only when the PSW has been confirmed, all documentation has been successfully approved and first samples have been accepted by customer. In case of manufacturing we fill the date, number of products, approve the Cp/Cpk capability of process, controling the samples according to QP.

       
       
       
       
              
    

27.1.2017, Janez Jurančič

       
              
              
 

Standard Measurement

  
     

Datum merjenja

Merilna oprema

Measurment equipment

Dimenzija

Dimension

Izmerjena vrednost

Measured value

CTQ            Y / N ?

Pregled in komentarji

Rewiew & Comments

 
 

Vzorec 1

Sample 1

Vzorec 2

Sample 2

Vzorec 3

Sample 3

Vzorec 4

Sample 4

Vzorec 5

Sample 5

Dobavitelj / Supplier

Kupec / Customer

 

Pregled /Rewiew

Komentar / Comments

Pregled /Rewiew

Komentar / Comments

 
              
                 
                 
 

MSA

 
   

Pregled in komentarji

Rewiew & Comments

Critical to Quality?

Datum merjenja

Merilna oprema

Measurment equipment

Dimenzija

Dimension

Toleranca

Tolerance

Izmerjena vrednost

Measured value

Dobavitelj / Supplier

Kupec / Customer

Zgornja tolerančna meja

Upper dimension

Spodnja tolerančna meja

Lower dimension

Vzorec 1

Sample 1

Pregled /Rewiew

Komentar / Comments

Pregled /Rewiew

Komentar / Comments

           
              
              

Simboli / Symbols:

 
 
 
    

CORRECTIVE ACTION REPORT

                    
                        
                            
    

Supplier Name:

                     
    

Attention:

 

Phone:

                 
    

Supplier no:

 

Report #:

                 
                              

1. Problem Description - Include facts (i.e., where discovered, by whom, when), specifications, references and attachments

                

Customer:

 

Purchase Order #:

                 

Customer Location:

 

Customer Part #:

                 

Date Issued:

 

Organization Part #:

                 

Issuer of report:

 

Part Name:

                 

Issuer Phone:

 

Quantity Shipped:

                 

Issuer email:

 

Quantity Rejected:

                 

Pieces were defected during die-casting process, which resulted that diameters are out of specifications. Diameter is out of specification by + 0,1 mm to + 0,2 mm above maximum tolerance of 5,20 mm.

                

(Photo/Sketch)

                 
                
                
                
                
                
                
                
                
                
                
                
                
                

 2.  Team Roster

                

 Name:

Organization:

Title:

Phone:

E-Mail:

                
                     
                     
                     
                     

3. Containment Action - Interim action to immediately isolate the effect of the problem

                

#

Task Description:

Assigned to:

Due Date:

Effective Date:

Results Achieved:

                

3a

Quarantine stock / stop delivery.

                    

3b

Sort stock.

                    

4. Root Cause Analysis - Underlying reasons why the problem OCCURED, why it was not DETECTED and why the related process, from a systemic viewpoint, ALLOWED the nonconformance to occur.

                

 4a.  Identification of Root Causes and Priority Ranking

(0 = No Impact, 1 = Low, 2 = Medium, 3 = High)

Rank         (0 - 3)

                

 Cause Categories:

Description

                

 People

 

2

                
  

2

                
  

2

                
   

3

                
  

2

                

 Methods/Procedure

 

3

                
  

3

                

 Equipment

  

3

                
                   

 Material

  

0

                
                   

 Environment

 

0

                
                   

 Measurement

 

0

                
                   

 4b.  Five-Why Analysis of Root Causes - Answer why the problem occurred AND why it escaped system controls

                

 Cause:

Why?

Why?

Why?

Why?

Why?

                
                      
                      

5. Corrective Action - Steps taken to eliminate root cause(s).

                

 The solution to this problem includes a detection mechanism or error-proofing device to prevent recurrence:     (  )  Yes       (  )  No      

                             

#

Task Description:

Assigned to:

Due Date:

Effective Date:

Results Achieved:

                
                      
                      
                      
                      

6a. Preventive Action - Steps taken to modify systems and procedures to prevent recurrence of a similar kind elsewhere

                

#

Task Description:

Assigned to:

Due Date:

Results Achieved:

                
                       
                       
                       
                       

 6b.  Read-Across - Steps taken to implement or share preventive action within other sites of the business unit or corporation.

                

#

Task Description:

Assigned to:

Due Date:

Results Achieved:

                
                       

7. Verification - Identify methods to verify completion and effectiveness of actions taken

                

 Verify the implementation and changes to:     (X)  Policies/Procedures       (X)  Work Instructions       (X)  FMEA       (X)  Control Plans       (  )  N/A

                             

#

Method:

Assigned to:

Due Date:

Results:

                
                     
                     

8a. Supplier Management Review - Endorsement and support by the organization responsible for correction

                
     

Date  

 

Phone:

                 

Originator's Name:

 

Sign:

  

Approved:

 

E-Mail:

                 
     

Date  

 

Phone:

                 

Top Management:

 

Sign:

  

Approved:

 

E-Mail:

                 
                              

8b. Final Closure - Parker responsible for closing Corrective Action Report

                

Quality Management

    

Date

 

Phone:

                 

Representative:

 

Sign:

  

Closed:

 

E-Mail:

                 
                              
                              
                              
           
             
             
           

 

           
            
            
          
           
            
          
            
           
     

 

      
          
        
          
          
         
           
            
          

 

          
        
           
            
            
     

 

      
          

 

          
           
         
        
           
           
           
            
            
           

 

     

 

      
          
           
           
           
           
    

 

      
          
          
          
         
          
         
          
            
             
            
             
             
             
             
             
             

Pareto Analysis

       

SUM OF PRODUCTS

       

Failure Type /Name

Nr. Failures

Procentage

Sum %

Nr. Produced

   
        
        

SUM

0

#DIV/0!

 

#DIV/0!

   
LibreOffice/6.0.7.3$Linux_X86_64 LibreOffice_project/00m0$Build-3 %



Pareto diagram - events

Nr. Events

 

       
        
        
                                       
 

DATE:

      

Failure Accumulation Chart

   
 

REVISION:

         
 

PREPEARED:

         
           
                                       

Gorenje

   

Assy Plant:

   

Time Period

   

Assy Line:

     
   

Test Character:

   

Part Description:

   

Test Frequency:

  

Department:

 
                                  

Total

LibreOffice/6.0.7.3$Linux_X86_64 LibreOffice_project/00m0$Build-3 % %

;

 

 
                                    

0

#DIV/0!

 
                                    

0

  
                                    

0

#DIV/0!

 

# of noncon. Parts

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

  

# of tested Parts

                                 

0

  

ppm:

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

 

#DIV/0!

            

#DIV/0!

  
 

5000

LibreOffice/6.0.7.3$Linux_X86_64 LibreOffice_project/00m0$Build-3

;

;

 

5000

 

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

 

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

5000

   

Control Limit (ppm)

                                    

5000

                                    
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                     
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                       
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                       

3

                       

10

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                           

Op A

13.95

13.95

13.96

13.99

13.98

13.96

13.94

13.92

13.9

13.95

13.95

13.94

13.91

13.92

13.91

13.98

13.94

13.95

13.95

13.95

13.96

13.96

13.96

13.95

13.97

13.97

13.96

13.97

13.96

13.96

13.9506666666667

                                                                           
                               

13.95

13.95

13.96

13.97

13.97

13.98

13.96

13.96

13.98

13.9644444444444

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                        

13.9533333333333

13.9733333333333

13.9666666666667

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
              

13.9533333333333

NaN

NaN

0.0100000000000016

NaN

NaN

 

13.9558888888889

0.0176666666666669

13.9739618888889

13.9378158888889

0.0454916666666672

                                                                           
                                                                           
                            

30

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                       

0

                       

0

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                           

Op A

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

                                                                           
                               

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

NaN

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                        

NaN

NaN

NaN

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                     

NaN

NaN

0

0

0

                                                                           
                                                                           
                            

0

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                       

3

                       

10

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                           

Op A

13.95

13.95

13.96

13.99

13.98

13.96

13.94

13.92

13.9

13.95

13.95

13.94

13.91

13.92

13.91

13.98

13.94

13.95

13.95

13.95

13.96

13.96

13.96

13.95

13.97

13.97

13.96

13.97

13.96

13.96

13.9506666666667

                                                                           
                               

13.95

13.95

13.96

13.97

13.97

13.98

13.96

13.96

13.98

13.9644444444444

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                        

13.9533333333333

13.9733333333333

13.9666666666667

                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
                                                                           
              

13.9533333333333

NaN

NaN

0.0100000000000016

NaN

NaN

 

13.9558888888889

0.0176666666666669

13.9739618888889

13.9378158888889

0.0454916666666672

                                                                           
                                                                           
                            

30